Snowmobile Ski Doo REV SERIES (2006 year). Instruction - part 105

Section 09 REAR SUSPENSION
Subsection 04 (SHOCK ABSORBER INSPECTION AND SERVICING)

Compress the carrier to access and remove the
snap ring.

All HPG T/A Shocks

With the seal carrier removed, slowly lift and
remove damper rod assembly from the damper
body.

NOTE: Remove damper rod assembly slowly to
reduce oil spillage and prevent piston seal damage
by damper body threads. Wrap the damper body
with a shop cloth to capture possible overflow oil
while removing the damper piston.

A27F0AA

1. Oil flows

Discard old oil into storage container. Never reuse
damper oil during shock rebuild.

HPG T/A Shocks Except with External
Reservoir

Remove valve core.

Using compressed air

pressure, carefully remove floating piston from
damper body. Hold shop cloth over damper body
opening to catch released floating piston. Allow
room for floating piston to leave damper body.

A27F06A

TYPICAL

HPG T/A Shocks with External Reservoir

Install floating piston remover tool (P/N 529 035
907) on shock absorber, as shown below.

A32F3YA

1. Floating piston remover tool (P/N 529 035 907)

Place shock absorber in a position where external
gas reservoir opened extremity is blocked. Refer
to following photo.

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Section 09 REAR SUSPENSION

Subsection 04 (SHOCK ABSORBER INSPECTION AND SERVICING)

A32F3ZA

1. Tool
2. Reservoir opened extremity blocked by leaning on work bench

With a low pressure hand pump, pressurize shock
absorber until external reservoir piston pops-out.

NOTE: Use towels to prevent damaging external
reservoir piston when it pops-out.



WARNING

Whenever using compressed air, use an
O.S.H.A. approved air gun and wear protec-
tive eye wear.

Thoroughly clean, with a typical cleaning solution,
and blow dry using low pressure air. Carefully in-
spect the damper body for any imperfections or
signs of wear in the damper bore.

Replace damper body if wear is identified.

All HPG T/A Shocks

Holding the damper rod assembly in a bench vise,
begin piston and valve removal.

A06F0UA

A. Remove damper nut

Always arrange parts removed in the sequence of
disassembly.

A06F0VA

NOTE: As a general rule we suggest replacing
the damper rod lock-nut after 4 rebuilds to ensure
good Iocking friction and use Loctite 271 (P/N 293
800 005) each time.

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Section 09 REAR SUSPENSION
Subsection 04 (SHOCK ABSORBER INSPECTION AND SERVICING)

NOTE: If revalving is to be done, it is imperative
that you identify the original shim pack (size and
number of shims). There is no need to remove
seal carrier if only revalving is to be done.

Shims can be measured by using a vernier caliper
or a micrometer.

NOTE: All shims should be carefully inspected and
any bent or broken shims must be replaced for the
shock to function properly.

After the new or replacement shim pack has
been selected, reassemble in the reverse order
of disassembly. Torque piston nut to 27 - 29 N•m
(20 - 21 lbf•ft).

A32F1WA

1. Damper nut
2. Spacer
3. Stopper with its round edge facing nut
4. Shim pack

CAUTION: The damper rod nut can only be
reused 4 times, then, must be replaced. Do
not substitute this part for non - O.E.M. use
Loctite 271 on nut each time.

This (these) spacer washer(s) must be used as
shown to ensure damper rod nut does not bottom
out or contact shaft threads.

Rebound valve stopper with round edge facing
nut.

NOTE: Rebound shim stack must not reach into
threads of damper shaft. Spacer under damper
shaft nut is used to prevent damper shaft nut from
bottoming on threads.

A32F1XA

1. Rebound dampening shim pack
2. Rebound dampening shim pack
3. Piston
4. Compression dampening shim pack
5. Compression dampening shim pack
6. Stopper

If the seal carrier assembly is replaced, use seal
pilot to guide seal over damper shaft. Lubricate
seal carrier guide pilot before use.

CAUTION: Failure to use seal pilot will result in
seal damage.

Reassemble damper rod assembly, taking care to
properly assemble shim packs as required for your
dampening needs. Ensure that the shaft piston
is installed with the slits/larger intake holes facing
the rebound shim stack.

A06F12C

1. Seal guide

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Section 09 REAR SUSPENSION

Subsection 04 (SHOCK ABSORBER INSPECTION AND SERVICING)

If floating piston has been removed, reinstall float-
ing piston into damper body (ensure that valve
core has been removed). Use Molykote G-n paste
(P/N 711 297 433) to ease O-ring past damper
body threads with floating piston guide.

CAUTION: Failure to install IFP correctly could
result in shock damage.

A06F14C

1. Push (slowly) by hand
2. Floating piston guide

NOTE: Lubricate inside of piston guide with
Molykote G-n paste (P/N 711 297 433).

Install floating piston to the proper depth refer to
following the table.

On all HPG take apart shocks, the floating piston
is installed hollow side up.

A27F0FD

A. Installation distance for floating piston installation

SHOCK P/N

INSTALLATION

DISTANCE OF

FLOATING PISTON

503 190 306

54.5

503 190 987

54.5

503 190 445

119.5

503 190 655

119.5

503 190 747

119.5

503 190 973

119.5

503 191 043

119.5

503 190 975

121.5

503 190 980

168

503 190 808

171.5

503 190 978

171.5

503 190 994

171.5

503 190 382

178.5

503 190 449

188

NOTE: If the floating piston is installed too far into
the damper body, light air pressure through valve
(with core removed) will move piston outward.

NOTE: Reinstall tire valve core after IFP has been
installed at correct height and before adding oil.



WARNING

Whenever using compressed air exercise ex-
treme caution, cover damper opening with
shop cloth to reduce chance of possible in-
jury.

CAUTION: Moisture laden compressed air will
contaminate the gas chamber and rust floating
piston.



WARNING

Always wear protective eye wear whenever
using compressed air.

Fill the shock with Bombardier HPG shock oil
(P/N 293 600 035) to approximately 10 mm
(.393 in), from the base of seal carrier threads.

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